Method of molding phenolic condensation products and the like



July 20 1926. 1,593,525

H. N. COPELAND METHOD OF MOLDING PHENOLIC CONDENSATION PRODUCTS AND THELIKE Filed 0G13. 5 1925 yy @a Patented July 20, 1926.

UNITED STATES .PATENT OFFICE.

HARRY N. COPELAND, OF DAYTON, OHIO, ASSIGNOB TO THE'KURZ-KASCH COMPANY,OF DAYTON, OHIO, A CORPORATION OF OHIO.

METHOD OF HOLDING PHENOLIC CONDENSATION PRODUCTS AND THE LIKE.

Application iled October 5, 1925. Serial No. 60,423.

My invention relates to the'molding of' phenolic condensation productsand the like, and more particularly to `the production in the moldedproduct of irregular grain-like i surface markings, somewhat inimitation of the irregular striate and rayonnant markings found inburlywalnut, mahogany, and other fine oramental wood. Phenoliccondensation material is molded in highy 4heated molds.y under heavypressure.

commercial -mixture of phenolic condensation products begins to fuse orbecomes plas'- tic at approximately two hundred 'to two h/undred twentydegrees and becomes fluid at approximately two hundred and sixty tothree hundred degrees. Beyond three hundred degrees, a chemical reactiontakes place, and the material, which at a lower temperature became softand then fluid, at the higher temperature sets or hardens. In

the usual method of operation, after the material has been fused 'at aflowing temperature and caused'to 4compfetely fill the mold by pressure,the temperature is increased to approximately three hundred andseventyfive degrees for a curing period, during which the molded productis hardened or set. Heretofore, it has been more or.less common practiceto produce articles of mottled appearance by intermixing material ofdifferent colors, prior to the introduction of material in themold,while yet in its original granular'or powder form. The` intermixtnre ofcolored material in the usual process wherein the material is heated toflowing temperaturel under. pressure and then set at av highertemperature, produces a more or less regular distribution of coloredstock, giving to the product a mottled appearance.

In the present instance, it has been d iscovered that by preforming thematerial into a tablet of such shape that itwill not initially fill the`mold space, but will leave re cesses therein, into which the materialis displaced under pressure as it becomes soft,

and by regulating the temperature, so that the material is displacedunder pressure into such open spaces, while in a viscous or plasticcondition, without becoming thoroughly liquefied, itV is. found that thecombination of, colored materials will form striae, sometimes radiatingfrom a central foci, and sometimesV scattered and confused, giving tothe distribution of the different The usual colors a curdled appearanceor hurled effeet, which is more or less controlled within reasonablelimits by the shape and arrangement of the material within the mold. Theobject of the' invention is to-provide a simple, efficient and effectivemethod of producing an ornamental irregular grain design, upon phenoliccondensation products somewhat in the imitation of burly effects of finecabinet wood.

A further object of the invention is to provide an improved process fortreating phenolic condensation material to produce pleasing effects bymolding at lowered temperature, and with ununif'orm distribution ot' thematerial within the mold.

In the accompanying drawings, wherein is shown the preferred steps forcarrying out the process, and illustrations of the product, Figs. 1 and2 are top plan views of radio instrument knobs, or the like, which havebeen adopted for illustrative purposes, the surface delineationshowingtwo of the endless possible effects which may be attained by thepresent process. Fig. 3 is a perspectwe view of the tablet or preformedcharge of phenolic condensation material,

`from which is produced, substantially the effect shown in Fig. 1. Fig.4 is a perspective view of twoshapes of preformed tablets or slu sofmaterial, which when employed togeter produce certain variations ormodifications of the rayonnant design shown in Fig. 1. Figs. 5, 6, and 7are sectional \views of molds for formin lsuch articles as radioinstrument knobs, il ustratin different forms of charge or tablet, anddi erent distribution of the material, within the mold to producedifferent ornamental desi n effects in the surface markings of the prouct. Fig. 8 illustrates a modification, wherein the surface marking isvaried by. a modification. .of the die in lieu of variations of thecharge or tablet. Figs. 9 to 14 are detail views, suggestive of variousshapes of v10e tablets or reformed charges of material to produced1erent grain.. or color designs or effects. j

Like parts are indicated by s1m1lar charac- `ters of referencesthroughout the several product has been adopted merely for illustrativepurposes, and lthat the invention is not limited to the production ofornamental 'surface markings upon radio knobs and dials, but may beapplied to various articles made from phenolic condensation products, towhich it may be desired to give ornamental appe arancesuch as automobilesteering wheels, electrical switch housings, buttons frames forpictures, or in fact any article which may be molded from phenoliccondensation products'.

Referring to the drawings, 1 indicates the male die and 2, thecorresponding female die or matrix forthe production of a radioinstrument knob. These dies 1 and 2 are steam heated or heated by other.means to al'ordthe necessary fusing and curing temperatures for thematerial. In the present rocess, the material of granular form andintermixed colors, is preferably"y preformed into a tablet, whichcontains the proper charge of material, by being coldpressed, so thatsuch tablet will maintain its shape. It has been found that by preforminthe tablet or charge into annular form, as sliown at 3, and subjectingsuch annular tablet charge within the mold to a comparatively low fusingtemperature of approximately two hundred to two hundredand forty degreesa rayonnant design, in which the striae of different colored materialextend outwardly from a central foci, as in Fig. 1 is produced. Theeffect of the design is controlled somewhat by variations intemperature. If the temperature is normally high, to fuse the` tablet toa flowing condition, the color mater1`al will bepmore or less evenlyintermixed,

and the striate design .will not be present in any marked degree.vvHowever, by fusing the material at a low temperature', whereby itbecomes plastic only or in a condition to flow but slowly, the increaseof pressure causes it to be displaced inwardly into the central opening4 of the annular tablet 3, and at the same time, the outer portion .ofsuch tablet is displaced outwardly and downwardly. vBeing in a plasticor thick viscous condition during its displacement, the color materialis plled inwardlyto fill the central opening 4; and at the same timepulled outwardly to form the side and margin of the product, therebyproducing radial fiow lines of the different colored material. which iowlines remain visible in the finished product, affording a highlyornamental and pleasing surface, somewhat 'in imitation of woodgraining. Various other effects can be produced by varying the shape ofthe tablet or charge. It has been found by experiment that by employinga solid tablet as.at 5, and superposing thereon a smaller annular tablet6, of less diameter, a differentv effect is produced, wherein therayonnant ydesign is not so decided nor extended as in Fig. 1,

l lesser extent.

rescates space 8 into which the material is displaced.

upwardly from the margin of the solid tablet 5 and also outwardly fromthe superposed smaller annular tablet 6.v It is this intermixing'of thematerial flowing in different directions, into the space 8', whichaffordsl the burled or confused stri effect, while the inward flow orpull of the color material as "it is displaced into the central o ening7,

produces the central rayonnant esign of A still further ornamentalburled effect somewhat similar to that illustrated in Fig. 2 ma beproduced by su erposing a. larger -ta let 10 upon a sma ler tablet 11 asin Fig. 7. In this instance, the larger tablet 10 being solid throughoutand devoid of the central opening before mentioned, therewould be noinward displacement of the material. However, the provision of thesmaller tablet 1l affords an annular space 12 into which the material ofboth tablets is displaced. The material of the smaller tablet `11 beingdis laced laterally and that of the larger tabllet 10 being displaceddownwardly, causes the material .to be intermixed, with more or lessconfusion about fthe periphery of the mold, thereby producing anirregular design, somewhat as illustrated in Fig. 2. To produce suchstriate design, whether of rayonnant or burled effect, the material isfused at a somewhat lower temperature than normal` that is. two hundredto two hundred and forty dagrees, so that it flows slowly in asemi-fluid or plastic state, .with the further rovision of a recess intowhich the, material 1s displaced while in such condition under pressure.This flow space can be variously provided, for instance, it is providedby the central orifices 4, and 7, of the annular tablet. or it may beprovided by forming a marginal offset or rabbet as at 8, ,on the u .perside of thecharge, or as at 12 on t e lower side of the charge. Eachvariation of the size, shape and osition of such iow space, produces avariation of the resultant design. Moreover,witli the flow spacesimilarl)7 positioned, the design may be varied by varyingthe initialfusing temperature, so that the material is flowed into such space orrecess, more or less quickly and in a more or less fluid condition. Inlieu of providing thefflow space in the charge itself, as heretoforedescribed, the die, either male or female may be provided With a recess13, as shown in 'Fig 8, into which the material will fioW with somewhatthe saine effect lwhen submitted to low fusing temperature.

If such boss formed by the mold depression is not desired in thefinished product, this boss may be removed subsequent to the removal ofthe product from the mold, leaving the surface ornamentation or design,produced by the movement of the material necessary to form such boss orprocess. In Figs. 9 to 14 there are shown suggestive forms or variationsof the initial tablet or charge. These may be made with endless variety,and by differently positioning the charge tablet, centrally or offcenter or superposing tablets of different shapes one upon another,within the mold, an endless variety of designs may be produced. h

Having thus described the invention, I claim 1. The herein describedmethod of procondensation products and the like, including distributingan intermixture of differently colored material ununiformly in the mold,fusing to a viscous state and subjecting to pressure by which thematerial is dis laced and distributed along flow lines de ned by striaeof colored material, and subjecting the molded product to a curingtemperature. n

2. The herein described\method of producin ornamental surface markingsupon pheno ic condensation productsand the like, including intermixingmaterial of different colors, fusing the intermixed material to aplastic condition under pressure to effect intersecting currents ofdifferently colored material WhileA plastic -thereby producing a striatedistribution of the colored materials and subjecting the product to acuring temperature. l

3. The herein described method 0f producin ornamental surface markings uon pheno ic condensation products and the like',

including intermixing differenltly colored materials and molding suchmaterial mixture at a comparativel low temperature under which thematerial is reducedto aA plastic condition effecting change of positionof the material within the mold there- (by producing in the product flowlines of differently colored materials, and subjecting the moldedproduct to a curing temperature.

4. The herein described ,method of pro-` 'which the material issubsequently displaced, heating the material to a viscous condition and'-subjecting it to pressure toN effect displacement into the fiow spaces,the, flow lines of sucli'displaeement being defined by striac'ofdifferently colored material.

, 5. The herein described method of producing ornamental surfacemarkings upon plienolicvcondensation products and the like, consistingin subjecting an intermixture of' differently colored phenoliccondensation materials to a comparatively low fusing temperature atlwhich the material is rendered plastic but maintained below a freefioiving state, molding such material under pressure by which thedifferently'colored materials Will be irregularly distributed indistorted masses Without blending or subdii'iding, and therebysin'iulating ai burly grain of cabinet Wood by such combinations.

6. The herein described method of producing a rayonnant design ofsurface mark- 0 I, ings upon phenolic condensation material ducingsurface markings upon phenolic articles, consisting in arranging anintel-mixture of differently colored materials in annular form, Within amold whereby there is afforded within the mold a central open recessinto which the material will flow, subjecting the material to fusingtemperature less than sufficient to reduce the material to a freeflowing condition, subjecting the fused material to pressure by which`converging flow lines of differently colored material are induced bythe displacement of the material into such central recess.

7. The herein described method of producing ornamental surface markingsupon articles molded from phenolic condensation materials and the like,consisting in intermixing differently colored materials, distributingthe material in a mold inV such manner as to leave an open recess intowhich the material may fioW When fused, fusing the material to asemi-fluid state and sub- .jecting the fused material to pressure byducing ornamental surface markings upon i articles moldedi from phenoliccondensation materials and the like, consisting in intermixingdifferently coloredmaterials, preformingfthe material into an annulartablet subjecting the tablet to fusing temperature under pressure toeffect a distorted irregular distribution of the colored material. p 9.The herein' described method of producing ornamental surface markingsupon articles molded from phenolic condensation materials and the like,consisting in intermixing differently colored materials, locating theintermixed material in a mold in such relation as to afford an annularsurlia' rounding flow space into which the material will he displaced9and subjecting 'the maten rial to fusing ,temperature under pressurethereloi7 causing the material to den' :into the surrounding;lspacewithin distorted irregn lar distribution ci the colored material.,

10 The herein descriloed method ot producing ornamental surface markingsupon articles molded 'from phenolic condensation materials and the like,consisting in inter mixing differently colored. materials, arranging theintermined material Within a mold in such iorrn as to leave an unlledspace into which the material Will he displaced, subjecting the materialto 'fusing temperature under pressure thereby displacn ing the materialnecessary to lill such space upon flow lines defined by irregulardistrin bution of the colored material ll. As an article of manufacturea phenolic condensation product having an orna mental striate surfacemarking produced by ununiform distribution of colored material somewhatin imitation oi ornamental calcinet Wood graining.

i. As an article of manufacture, an article molded from an intermixtureoi differently colored phenolic condensation materials wherein thediil'erentl] colored materials are arranged in irregular radiatingstriee.

i i3. As an article of manufacture, an article molded from. aninterrnixture of (liderently cofored phenolic condensation mate iials,wherein ilow lines of diierently colcred material are defined hydistorted stri., i 14. As an article of manufacture, an article moldedfrom an interinixture oi' difaccenno iferentlj] colored phenoliccondensation mau terials, wherein the diiferently colored roa- 'terialsirregularly distributed in imitation of hurly cabinet Wood graining.

l5. bis an article manufacture, an article molded l'roin aninterncixture oi diierently colored phenolic condensation inaterials,nai/ing the differently colored mate riale arranged in irregularrayonnant desien.,

lf2 A hotly ci intermixed' phenolic condensatior material oi diierentcolors preformed into an annular tablet preparatory 'to vfusing: in o,heated mold.

l?. A loody ot intermined phenolic condensation materials of did'erentcolors preiormed into talolet torni preparatory to fusin a mold. y

i8. The herein described method of producing surface markings uponmolded phenolic condensation products and the like,in cludingdistributing and intermixture of differently colored material in a mold,in such. manner as to leave o en spaces into which the material may loe`isplaced, fusing the material at a suhfnormal temperature by which thematerial loecomes mobile, hut not higzhlgT iluid, subjecting the fusedmaterial to pressure ley which relative movement of portions ofdiiierently colored material is affected, Within the mold Withoutblending, to produce in the molded article a series of distorted oWlines, defined hy the diiierently colored material.

InA testimony whereof, I have hereunto set my hand this 17th day ofSeptember A. D. l925.

HARRY N. COPELAND.

